Calibration method for hearing protection devices

ABSTRACT

Embodiments relate generally to hearing protection devices which incorporate a calibration mode which allows the user to perform a calibration test to determine an individualized hearing threshold. Embodiments of the device may also comprise a normal mode to prevent input signals greater than the individualized hearing threshold from being transmitted to the user&#39;s ear canal. In addition, embodiments may comprise a normal mode configured to limit input signals to less than or equal to a standard industry threshold in the case no calibration test has been completed by the user. This may increase user comfort and prevent hearing damage.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/349,054, filed on May 10, 2019 and entitled “Calibration Method ForHearing Protection Devices,” which is the national stage entry of andclaims priority to International Application No. PCT/US2016/061269,filed on Nov. 10, 2016 and entitled “Calibration Method For HearingProtection Devices,” each of which is incorporated herein by referencein its entirety.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

REFERENCE TO A MICROFICHE APPENDIX

Not applicable.

FIELD

Embodiments generally relate to improved hearing protection and, morespecifically, to hearing protection devices with speakers that serve toprotect the user's hearing from damage or discomfort due to speakervolume by allowing the user to calibrate the device to his/herindividual hearing threshold level.

BRIEF DESCRIPTION OF THE DRAWINGS

For a more complete understanding of the present disclosure, referenceis now made to the following brief description, taken in connection withthe accompanying drawings and detailed description, wherein likereference numerals represent like parts.

FIG. 1 illustrates a perspective view of an exemplary embodiment of anearmuff hearing protection device with external electronic elements;

FIG. 2 illustrates a cross-sectional view of an exemplary embodiment ofan earmuff hearing protection device comprising a processor, amplifier,speaker, and a sealing element;

FIG. 3 illustrates an overall diagram of an exemplary embodiment of asystem used to calibrate an input signal using a processor (and transmita sound through a speaker);

FIG. 4 illustrates, via a detailed diagram, an exemplary embodiment of asystem used to calibrate an input signal using a processor (and transmita sound through a speaker);

FIG. 5 illustrates, via a detailed diagram, an exemplary embodiment of asystem used to calibrate a left input signal and a right input signalusing a processor (e.g. for both ears of a user wearing an earmuff);

FIG. 6 illustrates, via a flowchart, a method of performing an exemplarycalibration test (for example using a user interface); and

FIG. 7 illustrates, via a flowchart, an exemplary operation of a hearingprotection device operable to run a calibration test to set anindividualized threshold.

DETAILED DESCRIPTION

It should be understood at the outset that although illustrativeimplementations of one or more embodiments are illustrated below, thedisclosed systems and methods may be implemented using any number oftechniques, whether currently known or not yet in existence. Thedisclosure should in no way be limited to the illustrativeimplementations, drawings, and techniques illustrated below, but may bemodified within the scope of the appended claims along with their fullscope of equivalents.

The following brief definition of terms shall apply throughout theapplication:

The term “comprising” means including but not limited to, and should beinterpreted in the manner it is typically used in the patent context;

The phrases “in one embodiment,” “according to one embodiment,” and thelike generally mean that the particular feature, structure, orcharacteristic following the phrase may be included in at least oneembodiment of the present invention, and may be included in more thanone embodiment of the present invention (importantly, such phrases donot necessarily refer to the same embodiment);

If the specification describes something as “exemplary” or an “example,”it should be understood that refers to a non-exclusive example;

The terms “about” or “approximately” or the like, when used with anumber, may mean that specific number, or alternatively, a range inproximity to the specific number, as understood by persons of skill inthe art field (for example, +/−10%); and

If the specification states a component or feature “may,” “can,”“could,” “should,” “would,” “preferably,” “possibly,” “typically,”“optionally,” “for example,” “often,” or “might” (or other suchlanguage) be included or have a characteristic, that particularcomponent or feature is not required to be included or to have thecharacteristic. Such component or feature may be optionally included insome embodiments, or it may be excluded.

The embodiments of this disclosure typically relate to improved hearingprotection, and might, for example typically relate to hearingprotection devices, such as earmuffs, having a speaker directed inwardtowards a user's ear. Typically, industry and/or regulations may have astandard sound level limitation for workers' noise exposure, for exampleover the course of a work shift. For example, a worker in an 8 hour workshift should not be exposed to sound over 82 A-weighted decibels (dBA)(e.g. based on The National Institute of Health and Safety (NIOSH) soundlevel limitation). Thus, if sound levels in the work environment areabove that limit, the use of hearing protection would be required.Additionally, if the hearing protection device has speakers (for exampleallowing sound to pass-through and/or radio communication and/orentertainment sound like music), then the speaker output should belimited to not exceed the sound level limitation in order to protect auser's ears from damage and/or discomfort. So, for example, speakersound in a hearing protection device might be limited to 82 dBA as astandard threshold (or some other limit set by industry or regulation).However, 82 dBA may not be an accurate sound level limitation for everyuser and may lead to impairment of the user's long term hearing abilitywith regular usage and/or user discomfort. This may be because each usermay have varying sound level sensitivity and efficiency as a result ofeach user having a unique shape and structure of the ear canal,thickness and area of the eardrum, and available number of sensinghairs. Additionally, users may have prior hearing impairment in one ear,resulting in different sound level limitations between the left ear andright ear. Thus, disclosed embodiments may allow the user to configurethe sound level limitation for an exemplary hearing protection devicebased on his/her hearing preference (e.g. individualized threshold).This may be accomplished by the user interacting with the system toperform a calibration test. The calibration test may be performed forboth ears at once (for example, both the left ear and right ear havingthe same sound level limitation) or the calibration test may beperformed individually for each ear (for example, the left ear having adifferent sound level limitation than the right ear). The user may alsochoose not to perform a calibration test to determine his/her ownhearing threshold, in which case the standard sound level limitation of82 dBA may be the standard/default sound level threshold for both ears.Thus, embodiments of the present invention may address one or more suchissues by allowing the user to configure the device to his/her ownhearing threshold in an attempt to prevent hearing damage and increaseuser comfort.

Disclosed embodiments relate to improved hearing protection, whichmight, for example, be used in hearing protection devices such asearmuffs. Alternatively, hearing protection devices might include eartips, ear plugs, headphones, or any other speaker for the ear (whichtypically blocks at least some environmental/surrounding noise).Typically, disclosed embodiments would include a speaker, a processor, auser interface, an input signal source, and, optionally, a sealingelement. For example, the sealing element may be configured to seal auser's ear canal and/or provide sound attenuation to protect the user'sears from potentially damaging external sounds and may function as ahearing protection device, such as an earmuff. The input signal sourcemay come from an external microphone (for external sound pass-through)which might be mounted on the exterior of the hearing protection device,a wireless communication device (such as a built-in radio communicatoror an external radio communicator transmitting to the speaker via a portor plug), or an entertainment device such as an iPod or mp3 player(which might be built-in or might be separate and input to the hearingprotection device by a port or plug). The user interface may be locatedon the exterior of the hearing protection device and may comprise one ormore buttons to allow the user to initiate and terminate calibration. Inother embodiments, the user interface may comprise voice or touchactivation, a biased switch, etc. Additionally, the user interface maybe another device, such as a handheld device, configured to interactwith the hearing protection device. The processor may be located withinthe hearing protection device and may interact with (e.g. beelectrically coupled to) the speaker. Typically, hearing protectiondevice embodiments would have two modes: a calibration mode and a normaloperating mode. In calibration mode, the processor may be configured torun a calibration test (by interacting with the speaker), therebygenerating an individualized threshold, which may be applied in normalmode to limit the input signal. Then, the speaker in normal mode maygenerate a sound based on a signal received from the processor withregards to the input signal. In some embodiments, there may be anamplifier located within the hearing protection device configured tocontrol the test sound volume/amplitude level at the speaker bycontrolling the test sound level signal. In this manner, the test soundvolume/amplitude level (during calibration testing) would be graduallyincreased, by increasing the test sound level signal during thecalibration test.

Typically, the hearing protection device may comprise two modes: acalibration mode and a normal mode. Generally, the user interface may beconfigured/operable to switch between the normal mode and thecalibration mode. In calibration mode, the processor would perform acalibration test (using the speaker) with input from the user (forexample the user indicating when the test sound level becomesuncomfortable) via the user interface. Once a calibration test has beenperformed, normal mode would typically comprise the processor cappingthe input signal (for example the processor reducing the input signaldownward if it is higher than what the user indicated is uncomfortable).In other words, calibration testing would generally only be run if/whenthe user prompts the system to initiate calibration mode (although insome embodiments, calibration testing might automatically occur onstart-up). In other instances, the system default would typically be torun in normal mode. During normal mode, in the case that the calibrationtest has been run and the user has completed the test to determinehis/her own individualized threshold (in other words, the maximum testsound level the user indicated was comfortable), the processor would capthe input signal at the individualized threshold level. However, in thecase that the calibration test has not been run and/or the user opted tonot complete the calibration test, the processor would cap the inputsignal at a standard threshold level (e.g. 82 dBA).

In an embodiment, for calibration mode, the user may initiate thecalibration test by using the user interface to place the hearingprotection device in calibration mode. During calibration mode, thespeaker may be configured to generate a test sound towards a user's earcanal based on a test sound signal from the processor (e.g. convert thetest sound signal (from the processor) into a test sound). Initially,the test sound may be set to a minimum test sound volume/amplitude levelby setting the test sound level to a minimum level with thevolume/amplitude of the sound being increased as the calibration testproceeds (until the user indicates discomfort or the sound reaches thestandard threshold). Typically, the test sound might be configured to beat one frequency, and for example might be a single frequency (e.g. apure tone at 1, 2, or 4 kHz). Thus, the processor would generallyincrease the test sound volume/amplitude level at one frequency duringcalibration testing. Keeping the test sound level at one frequency maydecrease the time it would take to complete the calibration test.Additionally, it may make it easier for the user to determine his/herindividualized threshold level. However, the test sound level may beconfigured by the processor to occur across multiple frequencies. Thismay increase the calibration test time, but increase the processor'sability to accurately cap input signals across multiple frequencies. Theprocessor may increase (e.g. incrementally) the test sound level bygenerating and transmitting to the speaker a test sound level signalwhich increases the volume/amplitude of the test sound over the previoustest sound level. Generally, the processor would keep increasing thetest sound level until the user deactivates the calibration test (forexample when the user determines the test sound level is uncomfortable)via the user interface causing a termination signal to be sent to theprocessor. However, in some embodiments, the processor may stopincreasing the test sound level if the user has not deactivated thecalibration test and the test sound level has reached the standardthreshold (e.g. 82 dBA). Once calibration testing has been terminated,the processor stores the maximum/last test sound level as theindividualized threshold. The individualized threshold may serve as acap, such that, in normal mode (with sounds having volume/amplitudegreater than the cap being reduced down to the cap threshold), novolume/amplitude greater than this cap would be transmitted into theuser's ear canal.

In an embodiment, once calibration mode has been deactivated, theprocessor may be configured to enter normal mode. Typically, duringnormal mode, the processor may be configured to cap the input signalbased on the individualized threshold stored during the calibration test(in the event a calibration test has been run), or the processor may beconfigured to cap the input signal at a standard threshold (e.g. 82 dBA)in the case no calibration test has been run. In the case calibrationhas been run, the processor may compare the input signalvolume/amplitude to the individualized threshold stored within theprocessor. For any input signal volume/amplitude greater than theindividualized threshold, the processor may reduce the input signalvolume/amplitude downward to the individualized threshold as thepass-through signal. On the other hand, for any input signalvolume/amplitude lesser than or equal to the individualized threshold,the processor may pass through the input signal volume/amplitude asunchanged. In the case no calibration test has been run (such that thereis no individualized threshold), the processor may compare the inputsignal volume/amplitude to the standard threshold (e.g. 82 dBA). For anyinput signal volume/amplitude greater than the standard threshold, theprocessor may reduce the input signal volume/amplitude downward to thestandard threshold as the pass-through signal. On the other hand, forany input signal volume/amplitude lesser than or equal to the standardthreshold, the processor may pass through the input signalvolume/amplitude as unchanged. Thus, in normal mode, any input signalvolume/amplitude that the processor measures, compares, and accepts orchanges via (software) processing and transmits to the speaker may beknown as the pass-through signal. In other words, the pass-throughsignal would be whatever portion of the input signal the processortransmits or passes through to the speaker (which would be capped ateither the individualized threshold or the standard threshold). In thismanner, the sound level transmitted to the speaker via the processor iscapped based on an individualized threshold or standard threshold toprotect the user's hearing over a period of time. While persons of skillshould understand the disclosed embodiments based on the abovedisclosure, the following figures may provide specific examples that mayfurther clarify the disclosure.

Turning now to the drawings, FIG. 1 illustrates a perspective view of anexemplary hearing protection device 100. The hearing protection deviceis depicted as an earmuff device in FIG. 1 and comprises two earcups101, each having speakers 103 and a sealing element 102; an externalmicrophone 107 (mounted on the exterior of the earcups); a wirelesscommunication device 108 (such as a built-in radio communicator); aport/plug 104 (operable to allow an external entertainment device suchas an iPod/mp3 or communication device or separate microphone (e.g.instead of one mounted on the hearing protection device) to provide aninput signal); and a user interface 106 including one or more buttons105. In FIG. 1, the user interface 106 is located on the exterior of thehearing protection device and may optionally comprise a screen (forexample configured to show the user which mode the device is in, whethercalibration mode is on or off, what the current individualized thresholdis, etc.). In other embodiments, there may be a light indicator (forexample configured to show the user if calibration mode is on (e.g.light is red) or if calibration mode is off (e.g. light is green)).Also, in some embodiments, the user interface 106 may comprise audiosoftware programmed to guide the user through calibration testing.Additionally, in the exemplary embodiment shown in FIG. 1, the userinterface 106 comprises one or more buttons 105 (to allow the user toinitiate and/or terminate calibration mode for example). In otherembodiments, the user interface 106 may comprise voice or touchactivation with regards to running calibration mode. Persons of skillshould appreciate the types of user interface elements which wouldfunction effectively to allow the user to initiate and terminatecalibration. Customarily, to activate calibration mode, the user maypress and hold the one or more buttons 105, and to deactivatecalibration mode, the user may release/depress the one or more buttons105. In another embodiment, the user may press and release the button toactivate the calibration mode and press and release the button a secondtime to deactivate the calibration mode. Additionally, in FIG. 1, theport/plug 104 configured to allow an external entertainment device toprovide an input signal is an auxiliary port, but a person of skillshould appreciate other types of ports/plugs 104 which would functioneffectively to connect an external device to the hearing protectiondevice to transmit an input signal.

FIG. 2 illustrates a cross-sectional view of an exemplary earcup 201embodiment of an earmuff hearing protection device comprising aprocessor 210, amplifier 220, speaker 203, and a sealing element 202.The processor 210 in the embodiment of FIG. 2 is a microcontroller unit(MCU) 210 which communicates with the amplifier 220, which thencommunicates with the speaker 203 to transmit sound to the user's earcanal. The MCU 210 further comprises memory which may compriseelectrically erasable programmable read-only memory (EEPROM). Duringcalibration mode, the MCU 210 may communicate with the amplifier 220 toincrease (e.g. incrementally) the test sound volume/amplitude levelsignal from a minimum test sound volume/amplitude level signal to amaximum test sound volume/amplitude level signal. Also duringcalibration mode, the amplifier 220 may communicate to the speaker 203to convert the test sound volume/amplitude level signal into a soundgenerated into a user's ear canal (at the correspondingvolume/amplitude). During normal mode, the MCU 210 may communicate withthe amplifier 220 to cap (e.g. decrease) the input signal 230 (or anyportion thereof in excess of the threshold) to either the individualizedthreshold (in the case that the calibration test has been completed) orthe standard threshold (in the case that no calibration test has beencompleted). The input signal 230 which is passed through the amplifier220 (and capped via the MCU 210) may then be a pass-through signal whichmay be transmitted to the speaker 203 to generate a sound. Additionally,in FIG. 2, the sealing element 202 configured to cover around theperimeter of the user's ear provides further protection against anexternal noise environment and reduces/attenuates the externalnoise/sound entering the user's ear canal. For example, the sealingelement 202 may provide a Noise Reduction Rating (NRR) of 20-32, 20-30,20-25, 22-25, 22-30, or 25-30, by way of example.

FIG. 3 illustrates an overall diagram of an embodiment of a system(typically used within a hearing protection device) used to calibrate aninput signal 330 using a processor 310. The input signal 330 may be froman input signal source which may be an external microphone, a wirelesscommunication device, or an external device such as an iPod/mp3 (forexample, via a port/plug in the hearing protection device) to provide aninput signal 330 to the processor 310. In FIG. 3, the processor 310 maybe configured to access its memory 312 to determine the user configuredparameters and to execute software processing. In some embodiments, thememory 312 may be an EEPROM, but in other embodiments, the memory 312may be in the form of RAM. Persons of skill should appreciate the typesof memory 312 technologies which would function effectively to storeinformation being processed by a processor (for example, a MCU). FIG. 3further comprises a switch 311 (which might typically interact with orbe a part of the user interface). In the embodiment of FIG. 3, theswitch 311 may be opened when the user prompts the user interface tobegin calibration mode. Upon termination of the calibration mode, theswitch 311 may be closed to indicate to the processor 310 to run innormal mode. In some embodiments, in normal mode, the processor 310 mayexecute software processing to reduce any input signals 330 greater thanthe individualized threshold (in the case that the calibration test hasbeen completed) or the standard threshold (in the case that thecalibration test has not been initiated or completed) and allow allother signals at or below the corresponding threshold to pass-through asan output signal 313. The output signal 313 may then be transmitted viaa transmitter/speaker 303 to the user's ears as sound.

FIG. 4 illustrates a more detailed diagram of an embodiment of a systemused to calibrate an input signal 430 comprising a switch 411, anamplifier 420, a sound generator 414, a digital potentiometer (POT) 415,a processor 410 (shown as MCU in FIG. 4), memory, and a speaker 403.During calibration mode, the user may initiate calibration testing viathe user interface. Upon initiation of calibration testing, the switch411 located directly after the input signal 430 may be opened to connectwith the sound generator 414 (e.g. so the input signal 430 is notelectrically connected to the speaker 403). When this occurs, theprocessor 410, which further comprises a clock generator 416 (shown asclock-out in FIG. 4) in this embodiment, may then be configured toproduce a (digital) timing signal to the sound generator 414. Then theprocessor 410 may instruct the sound generator 414 to generate astandard tone (e.g. 1, 2, or 4 kHz) (or alternatively generate a soundacross multiple frequencies). This would generally be accomplished bythe sound generator 414 which may be configured to transform the(digital) timing signal (from the clock generator 416) into the testsignal (which is an analog signal). Upon determination from the userinterface that the test sound level is acceptable (e.g. not too loud soas to be uncomfortable to the user), in the embodiment of FIG. 4 theprocessor 410 may implement its auto gain controller (AGC) 417 (shown asgain-ctrl in FIG. 4) to interact with the digital POT 415, which may beconfigured to interface with the amplifier 420 to steadily increase thevolume/amplitude of the test sound level. The processor 410 may continueincreasing the test sound volume/amplitude level until the userindicates the test sound volume/amplitude level is uncomfortable (viathe user interface). Additionally, the processor 410 contains ananalog-to-digital converter (ADC) 418 in the embodiment shown in FIG. 4.This may be due to the fact that the processor 410 processes data onlyin the digital form and the test sound signal levels may only betransmitted in analog form. The ADC 418 may pull/read the maximum soundlevel (signal) during calibration, which may then be recorded to thememory (for example, use of the individualized threshold in normalmode).

During normal mode, the switch 411 shown in FIG. 4 would generally beclosed to allow the input signal 430 to interface with the speaker 403(and, for example, via the amplifier 420, with the processor 410). Theprocessor 410 may then compare the input signal 430 with a standardthreshold (in the case no calibration test has been run/completed) or anindividualized threshold (in the case a calibration test has beenrun/completed). For any input signal 430 levels greater than thecorresponding threshold, the processor 410 may act to cap the inputsignal 430 (e.g. reducing such excess volume/amplitude downward to theappropriate threshold). For example, the processor's gain-ctrl 417 maywork in maximum gain by default and may follow a closed-loop feedbackregulating circuit to reduce the gain to match the threshold signallevel. This may be done by the gain-ctrl 417 interfacing with thedigital POT 415 to transmit a reduced input signal 430(volume/amplitude) to the amplifier 420 which may then further adjustthe volume/amplitude (upon determination the input signal 430(volume/amplitude) is greater than the corresponding threshold). Theprocessor 410 may be able to gather input signal 430 (volume/amplitude)levels via the ADC 418 to determine if the input signal 430(volume/amplitude) levels are acceptable (within the correspondingthreshold limit). Once the processor 410 determines the input signal 430(volume/amplitude) is less than or equal to the corresponding threshold,the processor 410 may pass the input signal 430 through as apass-through signal. The pass-through signal may then be transmitted tothe user's ear canal via the speaker 403.

FIG. 5 illustrates a detailed diagram of an embodiment of a system usedto calibrate an input signal (531, 532) similar to the detailed diagramshown in FIG. 4. The embodiment of a system shown in FIG. 5 comprisesthe following similar elements to the embodiment of a system shown inFIG. 4: input signal (531, 532), switch (511 a, 511 b), amplifier (520a, 520 b), speaker (503 a, 503 b), digital POT (515 a, 515 b), soundgenerator (514 a, 514 b), microcontroller unit (MCU) (510). However, inthis case, the system is configured for two ears. In other words, asshown in FIG. 5, there is a left input signal 531 (for example for theuser's left ear) and a right input signal 532 (for example for theuser's right ear). The user may choose to calibrate both ears at once(for example the switch (511 a, 511 b) after both the left input signal531 and the right input signal 532 may be open). The user may alsochoose to calibrate each ear individually (for example, the switch (511a) for the left ear is open to undergo calibration testing and theswitch (511 b) for the right ear is closed or vice versa). In FIG. 5,the switch 511 a for the left input signal 531 is open to indicate theuser may have initiated calibration testing for his/her left ear, andthe switch 511 b for the right input signal 532 is closed to indicatethe user may not have initiated calibration testing for his/her rightear (e.g. the right ear may be in normal mode).

In operation, calibration mode and normal mode for each ear in FIG. 5would essentially perform as described above with regards to FIG. 4. Inanother aspect, the disclosure includes two methods: a calibration modemethod and a normal mode method. The calibration mode method comprisescalibrating a hearing protection device with a speaker to an individualuser to determine an individualized threshold. The normal mode methodcomprises capping an input signal from an input signal source to theindividualized threshold (in the case the calibration test has beencompleted) or a standard industry threshold (e.g. 82 dBA) (in the casethe calibration test has not been completed). And often times, thenormal mode method of operation might follow the calibration mode methodof operation. The two methods are further described in the followingfigures which may provide specific method steps that may further clarifythe disclosure.

FIG. 6 illustrates a flow chart of a method of performing a calibrationtest. To enter calibration mode, the user interacts with the userinterface to initiate calibration 641. This may initiate the calibrationtest, by the processor, in response to an initiation signal receivedfrom the user interface. Once an initiation signal may be received, theprocessor generates a minimum test sound volume/amplitude level bysetting the test sound to a minimum test sound level 642 (whichtypically would be stored in the memory). The processor then generates aminimum test sound 643 (for example by communicating with the soundgenerator). In the case the user determines the test sound iscomfortable and does not deactivate calibration mode 644, the processormay instruct the amplifier to increase the test sound level 645 (signal)(for example in an incremental manner). Once the test sound level signalis increased 645, the processor instructs the sound generator togenerate the test sound 643. This may increase in test sound levelsignal (and the corresponding volume of the test sound) may continueiteratively (in a loop, as shown in FIG. 6), until either the standardthreshold is reached or the user deactivates calibration mode). In thecase the user determines the test sound is uncomfortable 644 andterminates the calibration test 646 (which may simultaneously deactivatecalibration mode), the processor stores the terminating/finalcalibration level (in memory) and enters normal mode 647 (for example asdiscussed below with regards to FIG. 7).

FIG. 7 illustrates a flow chart of a method of the hearing protectiondevice running in normal mode (which for example, might occur aftercalibration or alternatively if there has been no calibration). Theprocessor may run in normal mode at all times the hearing protectiondevice is receiving an input signal 751 via a sound signal source and isnot in calibration mode. Once the system receives an input signal 751(e.g. from a sound signal source), the processor may use softwareprocessing to determine if a calibration level (e.g. individualizedthreshold) has been set 752. Upon determining a stored calibration levelexists (for example within the processor's memory), the processor maycompare the input signal volume/amplitude with the calibration level.For an input signal volume/amplitude greater than the calibration level753, the processor reduces (caps) the input signal downward to thecalibrated level 757 (e.g. 82 dBA in the embodiment of FIG. 7) andtransmits the signal to the speaker 758. For an input signalvolume/amplitude less than or equal to the calibration level 753, theprocessor passes through the input signal unchanged as the pass-throughsignal 754. Upon determining no stored calibration level exists 752(e.g. within the processor's memory), the processor may compare theinput signal volume/amplitude with the standard threshold (e.g. 82 dBA).For an input signal volume/amplitude greater than the standard threshold755, the processor reduces the input signal downward to the standardthreshold 756 and transmits the signal to the speaker 758. For an inputsignal volume/amplitude less than or equal to the standard thresholdlevel 755, the processor passes through the input signal unchanged asthe pass-through signal 754. For all input signals that are passedthrough the processor as a pass-through signal 754, the processor maytransmit the pass-through signal to the speakers 758. The speakers maygenerate a corresponding sound into the user's ear canal.

Having described device and method embodiments above, especially withregard to the figures, various additional embodiments can include, butare not limited to:

In a first embodiment, a hearing protection device may comprise: asealing element (operable/configured to seal a user's ear canal toprotect against an external noise environment and/or reduce/attenuateexternal sound experienced by the user's ear canal); a speaker; aprocessor; a sound signal source operable to provide an input signal;and a user interface; wherein: the hearing protection device has anormal mode and a calibration mode; in calibration mode, the processoris configured to run a calibration test (by transmitting a test soundsignal to the speaker) to generate an individualized threshold (e.g.cap); and in normal mode, the processor is configured to apply theindividualized threshold to cap/limit the input signal (so that thespeaker will not generate sound in excess of the cap/limit (e.g. themaximum test sound level from the calibration test) to generate apass-through signal; and the speaker is configured to generate soundbased on the signal received from the processor. A second embodiment caninclude the hearing protection device of the first embodiment, whereinin calibration mode, the speaker is configured to generate a test soundbased on a test sound signal from the processor (e.g. convert the testsound signal (from the processor) into a test sound); and in normalmode, the speaker is configured to generate a pass-through sound basedon the pass-through signal (e.g. convert the pass-through signal intopass-through sound). A third embodiment can include the hearingprotection device of the first or second embodiments, wherein (incalibration mode) the processor is configured (e.g. by executingsoftware processing configured) to run the calibration test comprising:generating, by the processor, a minimum test sound (volume/amplitude)level signal and transmitting the minimum test sound level signal to thespeaker; (generating, by the speaker, in response to the minimum testsound (volume/amplitude) level signal, a minimum test sound);generating, by the speaker, in response to the test sound(volume/amplitude) level signal, the test sound (in the user's earcanal); (incrementally) increasing the test sound level (by theprocessor generating and transmitting to the speaker a test sound levelsignal which incrementally increases the volume/amplitude of the testsound over the previous test sound level); (continue (incrementally)increasing the test sound level); terminating the calibration test, bythe processor, in response to a first of: a termination signal from theuser interface; or the test sound level reaching a standard threshold(e.g. 82 dBA); and storing, by the processor (in memory/storage), themaximum/last test sound level as the individualized threshold (e.g. adBA or loudness/volume threshold) (which serves as a cap, such that novolume/amplitude greater than this cap will be transmitted into theuser's ear canal). A fourth embodiment can include the hearingprotection device of any of the first to third embodiments, wherein (innormal mode) the processor is configured to generate the pass-throughsignal (e.g. by executing software processing) comprising: comparing theinput signal (volume/amplitude) to the individualized threshold; for anyinput signal (volume/amplitude) in excess of the individualizedthreshold, reducing the input signal downward to the individualizedthreshold (so that the speaker in response will not produce sound overthe cap test sound level set during calibration) as the pass-throughsignal; and for any input signal (volume/amplitude) not in excess of(e.g. at or below) the individualized threshold, passing through theinput signal unchanged as the pass-through signal. A fifth embodimentcan include the hearing protection device of any of the first to fourthembodiments, wherein in the event no calibration test has been run, theindividualized threshold is the standard threshold. A sixth embodimentcan include the hearing protection device of any of the first to fifthembodiments, wherein in the event no calibration test has been run (suchthat there is no individualized threshold), the processor is configuredto generate the pass-through signal (e.g. by executing softwareprocessing) comprising: comparing the input signal (volume/amplitude) tothe standard threshold (e.g. 82 dBA); for any input signal(volume/amplitude) in excess of the standard threshold (e.g. pre-storedin memory of the processor), reducing the input signal downward to thestandard threshold (so that the speaker in response will not producesound over a standard cap sound level) as the pass-through signal; andfor any input signal (volume/amplitude) not in excess of (e.g. at orbelow) the standard threshold, passing through the input signalunchanged as the pass-through signal. A seventh embodiment can includethe hearing protection device of any of the first to sixth embodiments,wherein the user interface is operable/configured to switch betweennormal mode and calibration mode, and wherein in calibration mode, theuser interface is operable/configured to allow a user to set theindividualized threshold (e.g. by indicating when the test sound levelbecomes uncomfortable). An eighth embodiment can include the hearingprotection device of any of the first to seventh embodiments, whereinthe user interface is configured so that activation enters calibrationmode and initiates calibration testing, while deactivation sets theindividualized threshold and enters normal mode. A ninth embodiment caninclude the hearing protection device of any of the first to eighthembodiments, wherein the user interface is a button and whereinactivation is pressing (and holding) the button and deactivation isreleasing/depressing the button. A tenth embodiment can include thehearing protection device of any of the first to ninth embodiments,wherein the user interface is a button and activation is pressing thebutton and deactivation is re-pressing the button (subsequent to theinitial pressing that starts the calibration test). An eleventhembodiment can include the hearing protection device of any of the firstto tenth embodiments, wherein the sound signal source is one or more of:an external microphone (which might be mounted on the exterior of thehearing protection device/earcup); a wireless communication device (suchas a built-in radio communicator); a (built-in) entertainment device;and a port/plug (configured/operable to allow an external entertainmentdevice such as an iPod/mp3 to provide an input signal). A twelfthembodiment can include the hearing protection device of any of the firstto eleventh embodiments, further comprising an amplifier and a digitalpotentiometer, wherein in normal mode, the processor interacts with theamplifier via the digital potentiometer to adjust the input signal tothe pass-through signal. A thirteenth embodiment can include the hearingprotection device of any of the first to twelfth embodiments, furthercomprising a sound generator and an amplifier, wherein in thecalibration mode: the processor comprises a clock generator (e.g.clock-out); the clock generator is configured to produce a (digital)timing signal to the sound generator; the sound generator is configuredto transform the (digital) timing signal (from the clock generator) intothe test signal (which is an analog signal); and the processor furthercomprises the digital potentiometer configured to interface with theamplifier to control the test sound (volume/amplitude) level at thespeaker (e.g. by controlling the test sound level signal). A fourteenthembodiment can include the hearing protection device of any of the firstto thirteenth embodiments, further comprising memory storageconfigured/operable to store the individualized threshold from thecalibration test (and the standard threshold). A fifteenth embodimentcan include the hearing protection device of any of the first tofourteenth embodiments, wherein the processor is a microcontroller unitfurther comprising a clock generator, an auto gain controller, memory,and an analog-to-digital (ADC) converter. A sixteenth embodiment caninclude the hearing protection device of any of the first to fifteenthembodiments, further comprising an amplifier located between the soundsignal source and the user interface. A seventeenth embodiment caninclude the hearing protection device of any of the first to sixteenthembodiments, wherein the clock generator produces a timing signal withwhich to synchronize the sound signal generated by the sound generator,and wherein the auto gain controller (AGC) is configured to reduce theinput signal downward. An eighteenth embodiment can include the hearingprotection device of any of the first to seventeenth embodiments,wherein the test sound is a single frequency tone (for example 1, 2, or4 kHz) (or alternatively across multiple frequencies—e.g.multi-frequency sound/tone).

Exemplary embodiments might also relate to methods for calibrating ahearing protection device with a speaker to an individual user (e.g.similar to those described above, which may be considered optionallyincorporated herein with respect to the discussion of the methods). Suchmethod embodiments, for example, might include, but are not limited to,the following:

In a nineteenth embodiment, a method of calibrating a hearing protectiondevice with a speaker to an individual user, comprising the steps of:performing, by a processor coupled to the speaker, a calibration testconfigured to determine the user's individualized threshold (for use ina normal mode to limit/cap sound generation by the speaker, for examplein place of a standard threshold). A twentieth embodiment can includethe method of the nineteenth embodiment, wherein performing acalibration test comprises: generating, by the processor, a minimum testsound (volume/amplitude) level signal by initially setting the testsound level to a minimum level; transmitting the minimum test soundlevel signal to the speaker; generating, by the speaker, in response tothe test sound level signal, a test sound (in the user's ear);(incrementally) increasing the test sound level (by the processorgenerating and transmitting to the speaker a test sound level signalwhich incrementally increases the volume/amplitude of the test soundover the previous test sound level); terminating the calibration test,by the processor, in response to a first of: a termination signal from auser interface; or the test sound level reaching a standard threshold(e.g. 82 dBA); and storing, by the processor (in memory), themaximum/last test sound level as an individualized threshold (whichserves as a cap, such that no volume/amplitude greater than this capwill be transmitted into the user's ear canal). A twenty-firstembodiment can include the method of the nineteenth to twentiethembodiments, further comprising initiating the calibration test, by theprocessor, in response to an initiation signal from the user interface.A twenty-second embodiment can include the method of the nineteenth totwenty-first embodiments, wherein the hearing protection devicecomprises a calibration mode and a normal mode, and wherein initiatingthe calibration test places the hearing protection device in calibrationmode, while terminating the calibration test places the hearingprotection device in normal mode. A twenty-third embodiment can includethe method of the nineteenth to twenty-second embodiments, whereininitiating the calibration test comprises activating (for example bydepressing a button) the user interface, and terminating the calibrationtest comprises deactivating the user interface (e.g. button). Atwenty-fourth embodiment can include the method of the nineteenth totwenty-third embodiments, wherein terminating the calibration testoccurs when the user finds the test sound level uncomfortable. Atwenty-fifth embodiment can include the method of the nineteenth totwenty-fourth embodiments, wherein generating a test sound(volume/amplitude) level signal comprises the processor instructing asound generator to transmit a signal to an amplifier (and thereby to thespeaker). A twenty-sixth embodiment can include the method of thenineteenth to twenty-fifth embodiments, wherein the sound generator isconfigured to generate a sound at one (pure tone) frequency (e.g. 1, 2,or 4 kHz) (or alternatively across multiple frequencies). Atwenty-seventh embodiment can include the method of the nineteenth totwenty-sixth embodiments, wherein the processor comprises a clockgenerator (e.g. clock-out), and wherein the clock generator produces a(digital) timing signal to the sound generator (which the soundgenerator transforms into an analog signal); and wherein the processorfurther comprises a digital potentiometer which interfaces with theamplifier to control the test sound (volume/amplitude) level at thespeaker (e.g. by controlling the test sound level signal). Atwenty-eighth embodiment can include the method of the nineteenth totwenty-seventh embodiments, wherein the processor comprises amicrocontroller unit. A twenty-ninth embodiment can include the methodof the nineteenth to twenty-eighth embodiments, further comprisingsealing the user's ear canal (to protect the user from exposure toexternal noise from an external noise environment—e.g. by reducing theexternal sound entering the user's ear canal). A thirtieth embodimentcan include the method of the nineteenth to twenty-ninth embodiments,wherein the hearing protection device comprises two earcups, each havingspeakers, and being operable to seal the user's ears; and wherein themethod further comprises performing a calibration test for both ears. Athirty-first embodiment can include the method of the nineteenth tothirtieth embodiments, further comprising initiating the normal mode(e.g. by termination of calibration mode/terminating the calibrationtest); wherein in the normal mode, the processor caps an input signal(based on the individualized threshold). A thirty-second embodiment caninclude the method of the nineteenth to thirty-first embodiments,further comprising: receiving the input signal (by the processor);generating, by the processor, a pass-through signal (and transmitting tothe speaker); and generating a pass-through sound, by the speaker, inresponse to the pass-through signal. A thirty-third embodiment caninclude the method of the nineteenth to thirty-second embodiments,wherein (in the event the calibration test has been run) generating thepass-through signal comprises: comparing the input signal(volume/amplitude) to the individualized threshold; for any input signal(volume/amplitude) in excess of the individualized threshold (e.g.stored in memory by the processor during calibration test), reducing theinput signal downward to the individualized threshold (so that thespeaker in response will not produce sound over the cap test sound levelset during calibration) as the pass-through signal; and for any inputsignal (volume/amplitude) not in excess of (e.g. at or below) theindividualized threshold, passing through the input signal unchanged asthe pass-through signal. A thirty-fourth embodiment can include themethod of the nineteenth to thirty-third embodiments, wherein generatingpass-through sound, by the speaker, comprises generating sound based onthe pass-through signal which is no higher (in volume/amplitude) thanthe individualized threshold (e.g. cap or maximum test sound level, fromthe calibration test). A thirty-fifth embodiment can include the methodof the nineteenth to thirty-fourth embodiments, wherein, in the event nocalibration test has been run (such that there is no individualizedthreshold), generating the pass-through signal comprises: comparing theinput signal (volume/amplitude) to the standard threshold (e.g. 82 dBA);for any input signal (volume/amplitude) in excess of the standardthreshold (e.g. pre-stored in memory of the processor), reducing theinput signal downward to the standard threshold (so that the speaker inresponse will not produce sound over a standard cap sound level) as thepass-through signal; and for any input signal (volume/amplitude) not inexcess of (e.g. at or below) the standard threshold, passing through theinput signal unchanged as the pass-through signal. A thirty-sixthembodiment can include the method of the nineteenth to thirty-fifthembodiments, further comprising sealing (with a sealing element of thehearing protection device) the user's ear canal (to protect against anexternal noise environment or reduce/attenuate external noise/soundentering the user's ear canal). A thirty-seventh embodiment can includethe method of the nineteenth to thirty-sixth embodiments, wherein theinput signal is from one or more of: an external microphone (which mightbe mounted on the exterior of the hearing protection device/earcup); awireless communication device (such as a built-in radio communicator);and an entertainment device (such as an iPod/mp3, which might be inputto the hearing protection device by a sound signal source port or plug).A thirty-eighth embodiment can include the method of the nineteenth tothirty-seventh embodiments, wherein comparing the input signal(volume/amplitude) to the individualized threshold comprises comparingthe input signal to the individualized threshold stored in a memory ofthe processor (during the calibration test). A thirty-ninth embodimentcan include the method of the nineteenth to thirty-eighth embodiments,wherein generating the pass-through signal comprises the processorinteracting with an amplifier via a digital potentiometer to adjust theinput signal to the pass-through signal.

While various embodiments in accordance with the principles disclosedherein have been shown and described above, modifications thereof may bemade by one skilled in the art without departing from the spirit and theteachings of the disclosure. The embodiments described herein arerepresentative only and are not intended to be limiting. Manyvariations, combinations, and modifications are possible and are withinthe scope of the disclosure. Alternative embodiments that result fromcombining, integrating, and/or omitting features of the embodiment(s)are also within the scope of the disclosure. Accordingly, the scope ofprotection is not limited by the description set out above, but isdefined by the claims which follow, that scope including all equivalentsof the subject matter of the claims. Each and every claim isincorporated as further disclosure into the specification, and theclaims are embodiment(s) of the present invention(s). Furthermore, anyadvantages and features described above may relate to specificembodiments, but shall not limit the application of such issued claimsto processes and structures accomplishing any or all of the aboveadvantages or having any or all of the above features.

Additionally, the section headings used herein are provided forconsistency with the suggestions under 37 C.F.R. 1.77 or to otherwiseprovide organizational cues. These headings shall not limit orcharacterize the invention(s) set out in any claims that may issue fromthis disclosure. Specifically and by way of example, although theheadings might refer to a “Field,” the claims should not be limited bythe language chosen under this heading to describe the so-called field.Further, a description of a technology in the “Background” is not to beconstrued as an admission that certain technology is prior art to anyinvention(s) in this disclosure. Neither is the “Summary” to beconsidered as a limiting characterization of the invention(s) set forthin issued claims. Furthermore, any reference in this disclosure to“invention” in the singular should not be used to argue that there isonly a single point of novelty in this disclosure. Multiple inventionsmay be set forth according to the limitations of the multiple claimsissuing from this disclosure, and such claims accordingly define theinvention(s), and their equivalents, that are protected thereby. In allinstances, the scope of the claims shall be considered on their ownmerits in light of this disclosure, but should not be constrained by theheadings set forth herein.

Use of broader terms such as “comprises,” “includes,” and “having”should be understood to provide support for narrower terms such as“consisting of,” “consisting essentially of,” and “comprisedsubstantially of” Use of the terms “optionally,” “may,” “might,”“possibly,” and the like with respect to any element of an embodimentmeans that the element is not required, or alternatively, the element isrequired, both alternatives being within the scope of the embodiment(s).Also, references to examples are merely provided for illustrativepurposes, and are not intended to be exclusive.

While several embodiments have been provided in the present disclosure,it should be understood that the disclosed systems and methods may beembodied in many other specific forms without departing from the spiritor scope of the present disclosure. The present examples are to beconsidered as illustrative and not restrictive, and the intention is notto be limited to the details given herein. For example, the variouselements or components may be combined or integrated in another system,or certain features may be omitted or not implemented.

Also, techniques, systems, subsystems, and methods described andillustrated in the various embodiments as discrete or separate may becombined or integrated with other systems, modules, techniques, ormethods without departing from the scope of the present disclosure.Other items shown or discussed as directly coupled or communicating witheach other may be indirectly coupled or communicating through someinterface, device, or intermediate component, whether electrically,mechanically, or otherwise. Other examples of changes, substitutions,and alterations are ascertainable by one skilled in the art and could bemade without departing from the spirit and scope disclosed herein.

What is claimed is:
 1. A method of calibrating a hearing protectiondevice, wherein the hearing protection device comprises two ear cups,wherein each ear cup has a sealing element, a speaker, a processor, anda sound signal source, wherein the sealing element is configured tocover around a perimeter of the ear cup, wherein the processor and thespeaker are disposed inside the ear cup, the method comprising the stepsof: performing, by the processor coupled to the speaker, a calibrationtest configured to determine an individualized threshold of anindividual user, in a calibration mode, wherein the calibration mode isinitiated and terminated based on a signal, wherein performing thecalibration test comprises: generating, by the processor, a minimum testsound level signal, transmitting the minimum test sound level signal tothe speaker, generating, by the speaker, in response to the minimum testsound level signal, a test sound, increasing, by the processor, theminimum test sound level signal, in an incremental manner, in case theuser determines that a test sound signal is comfortable and does notdeactivate the calibration mode, terminating the calibration test, bythe processor, in response to a first of: a termination signal; or thetest sound level reaching a standard threshold; and storing, by theprocessor, a maximum test sound level as the individualized threshold;and initiating a normal mode, wherein, in the normal mode, the processoris configured to cap an input signal that is higher than theindividualized threshold to reduce the input signal to theindividualized threshold to generate a pass-through signal.
 2. Themethod of claim 1, wherein initiating the calibration test places thehearing protection device in the calibration mode, while terminating thecalibration test places the hearing protection device in the normalmode.
 3. The method of claim 2, wherein initiating the calibration testcomprises activating a user interface, and wherein terminating thecalibration test comprises deactivating the user interface.
 4. Themethod of claim 2, wherein terminating the calibration test occurs whenthe individual user finds the test sound level uncomfortable.
 5. Themethod of claim 1, wherein generating the minimum test sound levelsignal comprises the processor instructing a sound generator to transmita signal to an amplifier, and wherein the sound generator is configuredto generate a sound at one frequency.
 6. The method of claim 5, whereinthe processor comprises a clock generator, and wherein the clockgenerator produces a timing signal with which to synchronize the signalgenerated by the sound generator; and wherein the processor furthercomprises a digital potentiometer which interfaces with the amplifier tocontrol the test sound level at the speaker.
 7. The method of claim 1,further comprising: receiving the input signal; generating, by theprocessor, the pass-through signal; and generating a pass-through sound,by the speaker, in response to the pass-through signal.
 8. The method ofclaim 7, wherein, in an event the calibration test has been run,generating the pass-through signal comprises: comparing the input signalto the individualized threshold; and for any input signal not in excessof the individualized threshold, passing through the input signalunchanged as the pass-through signal.
 9. The method of claim 7, wherein,in an event no calibration test has been run, generating thepass-through signal comprises: comparing the input signal to thestandard threshold; for any input signal in excess of the standardthreshold, reducing the input signal downward to the standard thresholdas the pass-through signal; and for any input signal not in excess ofthe standard threshold, passing through the input signal unchanged asthe pass-through signal.
 10. The method of claim 7, wherein the inputsignal is from: an external microphone; a wireless communication device;or an entertainment device.
 11. A hearing protection device comprising:two ear cups, each ear cup having: a sealing element configured to coveraround a perimeter of the ear cup; a speaker; a processor, wherein theprocessor and the speaker are disposed inside the ear cup; and a soundsignal source operable to provide an input signal; wherein the speakerand the sound signal source are electrically connected with theprocessor; wherein: the hearing protection device has a normal mode anda calibration mode; in the calibration mode, the processor is configuredto run a calibration test to generate an individualized threshold,wherein the calibration mode is initiated and terminated based on asignal, and wherein the processor is configured to: generate a minimumtest sound level signal, transmit the minimum test sound level signal tothe speaker, cause the speaker to generate a test sound in response tothe minimum test sound level signal, increase the minimum test soundlevel signal, in an incremental manner, in case a user determines that atest sound signal is comfortable and does not deactivate the calibrationmode, terminate the calibration test in response to a first of: atermination signal; or the test sound level reaching a standardthreshold; and store a maximum test sound level as the individualizedthreshold; and in the normal mode, the processor is configured to applythe individualized threshold to cap the input signal that is higher thanthe individualized threshold to reduce the input signal to theindividualized threshold to generate a pass-through signal.
 12. Thehearing protection device of claim 11, wherein: in the normal mode, thespeaker is configured to generate a pass-through sound based on thepass-through signal.
 13. The hearing protection device of claim 12,wherein the processor is configured to generate the pass-through signaland configured to: compare the input signal to the individualizedthreshold; and for any input signal not in excess of the individualizedthreshold, pass through the input signal unchanged as the pass-throughsignal.
 14. The hearing protection device of claim 13, wherein in anevent no calibration test has been run, the processor is configured togenerate the pass-through signal and configured to: compare the inputsignal to the standard threshold; for any input signal in excess of thestandard threshold, reduce the input signal downward to the standardthreshold as the pass-through signal; and for any input signal not inexcess of the standard threshold, pass through the input signalunchanged as the pass-through signal.
 15. The hearing protection deviceof claim 11, wherein the sound signal source comprises: an externalmicrophone; a wireless communication device; an entertainment device; ora port or plug.